PowerMax PM4-15 - User Manual

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AC to DC Converter/Charger

AC to DC

CONVERTER/CHARGER

PM4 models 15, 35, 45, 55, 60, 65, 75, 100

and 120 Amp with Built-in 4 Stage Smart

Charging and Fixed Output Modes

Installation & Maintenance

Instructions

DISCONNECT DC POWER.

Disconnect the battery POS (+) wire at the battery end before connecting this Converter/Charger to any

vehicle/device wiring.

LOCATION.

The mounting location may be on any interior (out of direct weather) surface. Location chosen must be accessible after

installation. When mounted inside a cabinet, the cabinet must be large enough to allow dissipation of heated air. Make sure that there is a

minimum of 1” (one inch) free air space at each end of the unit so that cooling air can move through the unit properly. AVOID foreign

contaminants such as dirt, metal particles or moisture.

MOUNTING.

Flanges with holes are provided for ease of mounting using standard fasteners. Confirm that the surface that the converter is

mounted to is solid and will hold the weight (6 lbs) during vehicle operation.

ELECTRICAL REQUIREMENTS.

120 VAC

receptacle needs to be located within 36 inches of the Converter/Charger to supply power.

Electrical consideration should also be given to mounting near the locations of the batteries and the

12-volt DC

distribution panel.

ELECTRICAL CONNECTIONS

. Be sure to tighten all connections securely. A loose connection can quickly cause terminals and wires to

overheat. Review unit labels for recommended terminal torque values.

6. THE FAN WILL NOT RUN ALL THE TIME. THE FAN IS TEMPETUR CONTROLD AND WILL ONLY RUN WHEN NEEDED

Never Leave the PowerMax PM4-XX unattended when plugged in.

7. All PM4 Products must be installed by a certified electrician.

120 VAC

Connection – First confirm that the

120 VAC

power source AC circuit breaker(s) are in the

breakers until installation is complete.

position.

DO NOT

turn-on AC circuit

Using an 8 AWG minimum size copper wire, attach from the vehicle/device chassis to the Converter/Charger Bonding Lug.

Using the attached power cord on the Converter/Charger, connect firmly to the

120 VAC

receptacle

12 VDC

Wiring– It is important to use the correct wire gauge. Use a minimum of 8 AWG size copper wire.

The terminal marked

POS

is for the RV

12 VDC positive

connection.

NEG

is for the RV

12 VDC negative

connection.

The

12 VDC

output wiring does not require over-current protection because the Converter/ Charger limits current output. However, all

electrical connections need to comply with the appropriate NEC code.

FOR YOUR SAFETY, READ ALL INSTRUCTIONS BEFORE INSTALLATION AND OPERATION.

INSTALLER:

Provide these instructions to the end user or consumer.

CONSUMER:

Keep these instructions for future reference.

NOTICE: Products are not to be used nor are warranted in aerospace, medical or life safety applications.

SAFETY ALERT

120 VAC

is present. This Converter/Charger is designed to convert

120 VAC

12 VDC

. It also provides low voltage

power for charging on-board

12 VDC

batteries. The Converter/Charger is a “switch mode” type and is designed to be

maintenance-free with no user serviceable components. The Converter/Charger power output is “current limiting” by

design.

WARNING – Avoid Possible Injury or Death

NEVER store electrical devices in compartments where flammable liquids (such as gasoline) exist.

DO NOT mount/install unit in compartments designed for storage of batteries of flammable liquids.

WARNING – Avoid Personal Injury or Product Damage

WARNING – Avoid Possible Injury or Death

off

–

Need help?

Do you have a question about the PowerMax PM4-15 and is the answer not in the manual?

The PowerMax PM4 series are AC to DC Converter/Chargers designed to convert 120 VAC to 12 VDC and provide low voltage power for charging on-board 12 VDC batteries. These units are "switch mode" type and are designed to be maintenance-free with no user-serviceable components. The power output is "current limiting" by design.

Models and Specifications:

The PM4 series includes models with various amp ratings: 15, 35, 45, 55, 60, 65, 75, 100, and 120 Amp. All models feature built-in 4-stage smart charging and fixed output modes.

Installation:

Safety First: Always disconnect DC power by removing the battery POS (+) wire at the battery end before connecting the Converter/Charger to any vehicle/device wiring. Ensure the 120 VAC power source AC circuit breaker(s) are in the off position before connecting.
Location: The unit can be mounted on any interior surface, out of direct weather. When installed inside a cabinet, ensure the cabinet is large enough for heat dissipation. A minimum of 1 inch (one inch) free air space is required at each end of the unit for proper cooling. Avoid locations with foreign contaminants like dirt, metal particles, or moisture. Never store electrical devices in compartments with flammable liquids (e.g., gasoline) or mount the unit in compartments designed for battery storage.
Mounting: Use standard fasteners with the provided flanges and holes. Confirm the mounting surface is solid and can support the unit's weight (6 lbs) during vehicle operation.
Electrical Requirements: A 120 VAC receptacle should be within 36 inches of the Converter/Charger. Consider mounting near batteries and the 12-volt DC distribution panel.
Connections: Tighten all connections securely to prevent overheating. Refer to unit labels for recommended terminal torque values.
- 120 VAC Connection: Use an 8 AWG minimum size copper wire to attach from the vehicle/device chassis to the Converter/Charger Bonding Lug. Connect the attached power cord firmly to the 120 VAC receptacle.
- 12 VDC Wiring: Use a minimum of 8 AWG size copper wire. The terminal marked "+" or POS is for the RV 12 VDC positive connection. The terminal marked "-" or NEG is for the RV 12 VDC negative connection. The 12 VDC output wiring does not require over-current protection due to the Converter/Charger's current limiting, but all electrical connections must comply with the appropriate NEC code.

Usage Features:

4-Stage Smart Charging Mode (Factory Setting): This mode provides an automatic charging system with preset output voltages of 14.6V (Boost), 13.6V (Normal), and 13.2V (Storage).
1. Boost: A fast charge to rapidly bring a drained battery to full voltage.
2. Normal: A standard charge to bring the battery to full charge safely, prolonging battery life, and powering 12V lighting and appliances.
3. Storage: A trickle charge to keep the battery fresh during periods of low load activity. The charger automatically adjusts modes based on conditions. The fan is temperature-controlled and runs only when needed.
Fixed Voltage Mode: This mode allows the unit to directly power 12 Volt equipment or maintain the battery at a specific voltage.
- Setting Fixed Mode: With the unit off, move switch A to the "Fixed Voltage" position. Plug the unit into 110V power. Gently adjust switch B up or down to set the desired output voltage between 13V and 16.5V. The output voltage will remain constant at this level whenever the unit is powered on.
- Returning to Factory Settings: Power down the unit, move switch A to "Four Stage." Power up the unit and, with a voltage meter attached to the output terminals, gently adjust switch B up or down until 14.6V is reached.

Maintenance and Testing:

Initial Test (No Load): Disconnect all loads and the battery from the Converter/Charger by removing all 12 VDC connections from + or POS. Attach a multimeter between the positive and negative terminals. Energize the 120 VAC converter circuit. The output voltage should read 14.6 +/- 0.2 VDC.
Test with Load: Add 12 VDC load connections up to about 2/3 of the converter's rated capacity. Recheck the voltage, which should remain approximately the same as at no load. If the charger's output voltage is set below the battery voltage, it will not charge, and the LED will not illuminate.
Battery Connection Test: With the 120 VAC disconnected, reconnect the + or POS positive terminal to a known good battery. With the converter 120 VAC energized, measure the voltage at the converter and at the battery. The voltages should be approximately the same.
Battery Fluid Level: Regularly check the battery fluid level. Continuous connection to any charging source can cause batteries to "gas" and lose some fluid.
HI-POT Testing (Manufacturing Facilities Only): DO NOT Hi-Pot DC wiring with the Converter/Charger connected to the vehicle/device wiring to prevent serious injury and/or damage.

Troubleshooting:

Before removing or replacing the Converter/Charger, perform these checks:

Disconnect AC power from the vehicle/device.
Disconnect wiring and battery from the Converter Positive (+) output terminal.
Reconnect AC power to energize the Converter.
Using a voltmeter, measure the voltage at the Converter (-) and (+) Output terminals.
- If the voltage reading is between 13 VDC and 14 VDC (typically 13.6 VDC), the Converter is OK.
- Otherwise, consult the troubleshooting table:
  - No 12 VDC output: Possible causes include 120 VAC not connected or circuit breaker off, reversed battery fuses blown, severe overload or shorted load, or internal failure.
  - Converter cycles On & Off: Possible causes include inadequate or blocked fan air flow (ensure 1" minimum free air space), or internal failure.
  - Reversed Battery fuses blown: Possible causes include reversed battery wiring connections, defective battery, or bad cells.
  - 12 VDC output is too low: Possible causes include attached load exceeding rating, defective battery/bad cells, or internal failure.
  - LED light is not on: Possible causes include output voltage dropped below battery voltage (unit should start at 14.6V unless battery manufacturer recommends otherwise), or internal failure.

General Information:

Product Use: Products are not designed for and should not be used in life-support systems, nuclear facility applications, aircraft control applications, or any other applications where product failure could harm life, property, or the environment, without specific written consent from an officer of the supplier.
Warranty: Two-year limited warranty against faulty workmanship or defective materials. Liability is limited to replacing, repairing, or issuing credit for defective devices returned within the warranty period, provided the defect was not caused by misuse, neglect, improper installation, repair, alteration, or accident. All PowerMax products must be installed by a certified electrician.

PowerMax PM4-15 Specifications

General

Brand	PowerMax
Model	PM4-15
Category	Amplifier
Language	English